Ground Systems Integration Domain (GSID) Materials for Ground Platforms

20 SEP 2010

Ms. Lisa Prokurat FranksMaterials EngineerOffice of the Chief Scientist

UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE

UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE

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1. REPORT DATE 20 SEP 2010

2. REPORT TYPE N/A

3. DATES COVERED -

4. TITLE AND SUBTITLE Ground Systems Integration Domain (GSID) Materials for Ground Platforms

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) Lisa Prokurat Franks

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI48397-5000, USA

8. PERFORMING ORGANIZATION REPORT NUMBER 21199RC

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI48397-5000, USA

10. SPONSOR/MONITOR’S ACRONYM(S) TACOM/TARDEC

11. SPONSOR/MONITOR’S REPORT NUMBER(S) 21199RC

12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release, distribution unlimited

13. SUPPLEMENTARY NOTES The original document contains color images.

14. ABSTRACT

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATIONOF ABSTRACT

SAR

18. NUMBEROF PAGES

39

19a. NAME OFRESPONSIBLE PERSON

a. REPORT unclassified

b. ABSTRACT unclassified

c. THIS PAGE unclassified

Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

Tank Automotive Research, Development & Engineering CenterDr. Grace Bochenek, Director

Overview

Distribution approved for Public Release; distribution Unlimited, per AR 380-5. OPSEC Review conducted per AR 530-1 and HQ TACOM OPSEC SOP #20587

Responsible for Research, Development and Engineering Support to 2,800 Army systems and many of the Army’s and DOD’s Top Joint Warfighter Development Programs

Mission

Ground Systems Integratorfor the Department of Defense

– Provides full life-cycle engineering support and is provider-of-first-choice for all DOD ground combat and combat support vehicle systems.

– Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force.

Unclassified 2

Army

Materiel

Command

(AMC)

TACOM

LCMC

(ASA(ALT))

ILSC

ACQ

Center

Industrial

Base

PEO

GCS

PEO

CS&CSS

PEO

Soldier

PEO Integration

Department of

the Army (DA)

Armament Research, Development and Engineering Center (ARDEC)

Army Research Laboratory (ARL)

Edgewood Chemical and Biological Center (ECBC)

Aviation and Missile Research, Development and Engineering

Center (AMRDEC)

Natick Soldier Research, Development and Engineering Center

(NSRDEC)

Communications-Electronic Research, Development and Engineering Center

(CERDEC)

Simulation and Training Technology Center (STTC)

Research, Development and Engineering Command

(RDECOM)

3Unclassified

Organizational Relationships

Army Materiel Systems Analysis Activity (AMSAA)

Reach back to over 8,500 Scientists and Engineers

Senior Research Scientist - Robotics

Organizational Structure

4Unclassified

TARDEC Director

Chief ScientistExecutive Director

of Engineering

Systems Engineering

Life-Cycle Data Management

RAM, Test & QualityAssurance

Standardization &Transportability

Software Engineering Center

Industrial Base Engineering Support

Executive Director ofProduct Development

Center for Ground Vehicle Development

& Integration

Force Projection Technology

National AutomotiveCenter (NAC)

Executive Director of Research & Technology

Integration

Concepts, Analysis,Systems, Simulations

& Integrations (CASSI)

Ground SystemsSurvivability

Intelligent Ground Systems

Ground Vehicle Power & Mobility

Joint Center for Robotics

Vehicle Electronics & Architecture

Military Deputy

Chief of Staff

Foreign Vehicle Specs & Materials Eng

Eng – Systems in Acquisition

Combat Vehicles • Heavy Brigade Combat Team• Strykers• MRAPs• Ground Combat Vehicles (Future)

Tactical Vehicles• HMMWVs • Trailers• Heavy, Medium and Light

Tactical Vehicles

Force Projection• Fuel & Water Distribution • Force Sustainment • Construction Equipment • Bridging • Assured Mobility Systems

Robotics• Technology Components• Demonstrators• Military Relevant Test & Experimentation• Transition & Requirements Development

5Unclassified

Portfolio

TARDEC Engineers Provide Cradle-To-Grave Engineering Support

System & Simulation Integration Laboratories

Laboratory Capabilities

Grease & Hydraulic Fluid Lab

Fuels & Lubricants Laboratories

Coolant Lab Fuel & Lube Lab Analytical Lab

Physical Simulation Laboratories

Vehicle Inertial Properties Evaluation Rig

Reconfigurable N-Post Simulator Multi-Axial Simulator

Survivability Laboratories

Ballistic Testing

Center for Ground Vehicle Development & Integration

Large Robotics Integration Cell

Prototype Integration

Ground Systems Power & Energy Lab

Propulsion Laboratories

6

Power & Energy Laboratories

Unclassified

TARDEC’s Warren, MI operations has a resource value of over $950M and occupies 12 facilities on the Detroit Garrison totaling over 840,000 square feet of laboratory space

Concept Development Modeling & Simulation Environment

System Evaluation MRAP Systems Integration Lab

Material Initiatives and Needs for Lightening Ground Platforms

11 March 2010

Dr. Douglas TempletonUS Army TARDEC

UNCLASSIFIED: Dist A. Approved for public release

Motivation

• Lightweight/Mobile

• Threat Designable/Repairability

• Armor: Multifunctional Ballistic/Structural/Stealth

DRIVERS

PERFORMANCE

PROTECTION PAYLOAD

NEED TO BALANCE

The 3 Ps!

UNCLASSIFIED

Importance of Basic & Applied Research

Brittle Materials:• Material properties• Processing/synthesis• Ceramic optimization• Failure mechanisms • Failure morphology• Dynamic behavior modeling• Laboratory characterization

techniques

· Determination of properties

relevant to ballistic impact

Mechanics of Composites

- Finite element codes

- Strength of materials

- Analysis of thick composites

- Micro scale model

Penetration Mechanics:

- Constitutive material models

- Hi-strain rate propagation

- Metallurgy

- Hydrocode development

Armor Mechanics:•-Defeat Mechanism• Encapsulation Techniques• Ceramic Optimization• Multi-hit• Structural Response• Ballistic Shock• Modeling• Trends analyses

· Armor optimization

· Initial trades studies/analyses

Structural Design Tech:• Design trades• LW structural Response

Structure• Load optimization• Attachment design• Shock/vibration• Damage tolerance• Affordability• RAM

Platform integration,

producibility, and

performance testing

Basic Research

Applied Research

Adv Development

Eng Development

INITIATION

IOC

Basic research critical to success, and must be a CONTINUING activity

Armor module dev/fab• Robustness • Manufacturability• Attachment design• Shock transmission• Affordability• RAM

Trades analyses • Performance• Weight• Cost

UNCLASSIFIED

Materials for Ground Platforms

–Ideal situation: materials readily available and fully developed.

• RHA

• High hard steel

• Aluminum

–Reality: Research projects are ongoing to further develop advanced lightweight armors.

• Composites

• Ceramics

• Titanium

• Magnesium

• Composite and

metal matrix

–Long Term Armor Strategy

• A + B design

• Requirements are classified

UNCLASSIFIED

Design Drivers –Cost/Weight/Volume

• Silicon Carbide Armor Tile Comparison at Equivalent Ballistic Protection

• (production cost)

• Titanium & Aluminum/Lithium Alloy Raw Material Cost

~$12/lb vs. ~$4/lb for Conventional Aluminum

SiC

Composite

SiC

Titanium TitaniumSpall Liner

Alumina

Titanium

Spall Liner

Alumina

Composite

20-23 psf$80/lb*1.0-1.5”

20 psf$80/lb*1.65”

40 psf$30/lb*1.75”

30 psf$35/lb*2.15”

30-33 psf$50/lb*1.5-2.0”

UNCLASSIFIED

Structural Approaches

• Space Frame

–Lightest “structure only” weight

–Tailorable survivability

• Ballistic armor tailored to mission requirements

• Low burden integration of other enhancements.

–Ease of repair

–Improved transportability

MonocoqueSpace Frame

MonocoqueLightest weight approach assuming a base level of ballistic protectionEfficient integrated structural armor solutionsMaximum interior volumeLowest cost

Hybrid Structures

UNCLASSIFIED

Combat Vehicles

• Thick, heavy armor

• Structure as by-product of armor

• Inherently damage tolerant

• Arrive on ships

• Well understood materials and manufacturing practices

• Designed for force-on-force engagement

• Cumbersome logistics tail

• Basic situational awareness

• Lightweight armor

• Structure plus armor (A + B)

• Relatively damage intolerant

• Air transportable (C-130)

• Advanced ceramic armors, use of polymer composites and associated mfg. practices

• Designed for noncontiguous, non-linear, reorganizing battlefield

• Common components, reduction of logistics footprint

• Network centric, highly interdependent

Current Future

UNCLASSIFIED

Issues to LightweightingCombat Vehicles

• Development of survivable vehicle systems while keeping to air transport weight (aircraft dependent)

• Attachment methodologies for A + B armor concept, appurtenances

• Joining and fastening technologies (dissimilar materials), adhesives

• Balancing interior volume against the use of less efficient structural material solutions

• Signature management, electromagnetic shielding over potentially non-metallic surfaces

• Diagnostics & prognostics for structural health assessment

• Material costs and improving multi-hit performance

• Advanced structures offer part consolidation necessitating development of high yield mfg. processes

• Inspection and repair of advanced armor systems

• Improved modeling and simulation

Frame Assembly

Composite Upper Skin

Conceptual Designs

Armor Module

UNCLASSIFIED

Tactical Vehicles

• Tired and aging fleet

• Corrosion prone

• Cabs typically unarmored. Armoring via add-on-armor kits

• Reduced vehicle payload, maneuverability, reliability, safety, maintainability, and life expectancy

– Increased wear and tear on vehicle components, fuel consumption, and life cycle costs

• Multiple original equipment manufacturers, little commonality

– Designed for traditional role of logistics support

• Recapitalization with appliqué armor (A-kit/B-kit)

• Be more survivable in mine blast events

• Component commonality (hardware, transparent armor, B-kit panels

• Gun turret and advanced countermeasures

• Crew installable B-kit, with minimal tools

• Enhanced crew survivability to meet threat

• Increased system reliability

• Taking on more of an assault role

Current Future

UNCLASSIFIED

Issues to lightweightingTactical Vehicles

• Balancing material costs over a large vehicle fleet

• Integration of hybrid, advanced materials, and layered armor solutions

• A-frame with mounting points which allow for rapid addition/removal of B-kit, and spiral-in of emerging armor technologies

• Addressing seams and edges that result from modular armor

• Tile confinement for enhanced ceramic armor performance

• Improving armor multi-hit performance of advanced armors

• Opaque armors under 28 psf and transparent armors under 30 psf

• Keeping transparent armor thickness to a minimum

• Durability of advanced lightweight armors

• Health assessment of advance armors

• Improved modeling and simulation

A-Kit/B Kit Concept

UNCLASSIFIED

Validated Design and Analysis Tools

• Quarter Section TestingFlexureShearIn-plane

Experimental Database for

FEA

Database for Development and

Validation of Laminate Modeling

Develop analysis tools critical for structural design

Sub-element Testing Required

UNCLASSIFIED

SUMMARY Of Material Initiatives and Needs for

Lightening Ground Platforms

• Significant challenges remain in areas of material development

• Need to look at not just basic materials but structural approaches

• Modeling and simulation is a critical enabler

UNCLASSIFIED

Ground Systems Integration Domain (GSID) Workshop on Materials for Ground Platforms

University Center - Macomb Community College

Clinton Township, MI

August 23-24, 2010

Unclassified

Unclassified

Ground Systems Integration Domain(GSID)

21

Unclassified

Holistic Approach to Ground Combat Vehicle Platform Innovation

RDECOM will rapidly develop platform designs and demonstrators driving innovation in the areas of ground platform survivability and mobility.

Platform Weight Class Project PartnersProject Objectives

• Novel, inventive vehicle design approaches• Rapid acquisition (12-18 month timelines)• Extensive use of M&S tools to optimize design• Non-tradition defense project partners

• Embedded with ARCIC to drive requirements generation for future platform requirements

Driving Innovation across the Ground Community:

Project Schedule

14,000 - 16,000 lbsLight Tactical

• 30% Fuel Economy Improvement over M1151

• Maintain Mobility of M1114

• MRAP Threshold Survivability

• <14,000 lbs Vehicle Weight

• System Cost of $250,000

• 18-24 months from Concept to Build

• 12 month Tech Discovery phase

• 12 months from Design to Build

40,000 - 60,000 lbs

Medium Combat• S-MOD/MPC Threshold Survivability

• M1 Equivalent Mobility

• Motor Sports Vehicle Design Process• 12-18 months from Concept

to Build (tentative)

100,000 - 140,000 lbsHeavy Combat

• Soldier-Centric Vehicle Design

• Modular, Reconfigurable Vehicle Systems

• ~36 months from Concept to Design (Includes tech

development)

• Targeting selected GCV Objective Requirements

Professional Motorsports

Industry

• FED Program–OSD Funded

ACT VI Project

Ricardo

WTSI Global Services

HardwireComposite Armor Systems

Unclassified

Light TacticalOverarching Research Objectives

Primary Research Objectives (Occupant-Centric Survivability Focused):

1. 4500 lbs + trailer towing capacity; 4-6 man crew compartmentPayload

2. 14,000 lb curb vehicle weightPerformance

4. $250,000 base vehicle (@ 10K Qty)Price

5. 12 monthsSchedule

3. MRAP threshold survivability employing modular base armorProtection

Secondary Research Objectives (Light Tactical Vehicle Key System Attributes):1. Select JLTV requirements as secondary research objectivesPerformance

Double V-Shaped Hull

HDX Modular Armor (Spall, A-Kit, B-Kit, C-Kit & RPG Defeat Interface)

Virtual Transparent Armor

SBC (Lightweight Blast Mitigation System)

High-Energy Double Duty Lithium Ion Batteries

Hybrid Electric Propulsion System

Computer-controlled Magnetorheological (MR) Semi-Active Suspension

Modular Drivetrain & Suspension

Projected Cost:$20M

Unclassified

Workshop Expectations

• Research Driven Opportunities

– 6.1, 6.2 -> What should the GSID follow and support?

– Awareness and participation in Material Science Programs

• Opportunities to integrate

– Demonstrator programs (6.3)

– Platform/Product/Part Driven Needs

• PEO GCS, CS&CSS modernization programs

• OEMs

• DLA/Sustainment

• Depots

• Barriers to adoption of new materials?

– Environment, safety, cost, weight, size, MRL/TRL

Unclassified

From PEO CS&CSS (23AUG 2010)

How to cross the “Valley of Death” transitioning a technology into an acquisition program

• Most commonly from Army S&T (6.3 funded) TRL-6 to a Program of Record (6.4+)

• Know the Technology Readiness Level (TRL) of your technology

• Get to know the target platform

– Where is the program in its lifecycle?

• Determines the amount of each of the funding types available to the PM

• Determines the maturity of the technology (TRL) the PM can accept (for example: TRL-6 at MS-B)

– Technologies going into a POR undergo Technology Readiness Assessments (TRA)

– What is the POR’s acquisition strategy – COTS or Developmental?

– PMs must have a requirement, validated by TRADOC, to acquire technology

• Understand the transition pathway – this is for you to have fully worked out

– Does your technology have to be integrated in another manufacturer’s system?

– Can you manufacture your technology in quantity?

• Cost matters!

TRL-4 TRL-6 TRL-7 TRL-8 TRL-9

TRA TRA

Unclassified

From PEO GCS (23AUG 2010)

Overarching

26

• Review of the ongoing activities in RDECOM, DARPA, academia, industry, partnering, and structured analysis to identify best opportunities-Funnel thru GSID

• Safety: During production through Hostile Engagement

• Primary: Power, survivability, communications, lethality

• Environmentally safe and nonhazardous

• Reflect heat, absorb solar energy to power batteries, shock absorbing (external and internal)

• EMI friendly so we can add antennas and retain low signatures

• Repeated heat/cold cycles.

Unclassified

From PEO GCS (23AUG 2010)

Prioritized Capability Gaps

Unclassified

From PEO GCS (23AUG 2010)

-ilities for the Platforms

• New survivability materials must have good durability to last until needed Synergetic effects of armor metallic (AL, STL, TI) laminated with ballistic liners (Kevlar, E-glass, S-glass....)

• Reduced flammability: Don’t put polyethylene base composite inside the vehicle such as Dyneema, Tenselon, Spectra

• Maintainability to allow field removal, replacement and/or repair: suitable chromium replacement

• Compatibility to resist corrosion and/or fungus

•Affordability with no negative impact on SWaP-C -lightweight structures

• Materials for power electronics'–Suitable lead-free solder–Efficiency and increase operating temperature(i.e. SiC, magnetics)–Batteries to increase energy/power density(i.e. LiIon, energy dense cathodes )

• Polymers for suspension and track

• Lubricants: Single lube forward compatible with VHM Sensors

Unclassified

PEO Material Property Needs

• Strength

• Lightweight

• Manufacturable

• Maintainable

• Corrosion and fungus resistant

• Environmentally friendly

• Low-cost

• Reduced flammability materials

• Long life

• End-of-life plan

29

Unclassified

PEO Needs - Specifics

• Replacement for Cr

• Lead free solder

• Replacement for Halon

• Polymers for suspension and track

• Improved metals, glass, cloth

• Energy storage materials

• Bridging technologies – bridge, boat, trucks, health monitoring

• Propulsion systems to burn JP8 without sacrificing sensors

• Packaging for water and fuel

• Single lube compatible with existing sensors

30

Unclassified

R&D Agencies Represented

• ARDEC

• ARL

• ARL WMRD

• ARO

• DARPA

• DOE-ORNL

• DOE-PNNL

• DOE-VTP

• NIST

• PEO CS&CSS

• PEO GCS

• TARDEC

• USACE-ERDC

31

Unclassified

Lightweight materials

• Metals, alloys– Advanced High Strength Steels – many varieties

– Titanium – needs work to produce inexpensively

– Magnesium

– Structural amorphous metals

• Non-Metals– Composites of every variety

• Carbon fiber

• Graphene

• Glasses

• Ceramics

• Polymeric fibers

– Boron carbide

32

Unclassified

Materials of the Future

• Nanomaterials– Nano grain sizes

– Carbon

– Coatings

• Bio-inspired materials

• Structured architectures

• Self-healing

• Damage sensing elastomers

• High-strength fibers

• Armors that spread the energy

• Foams, lattice materials

• Chemical manipulation

• Unprecedented properties

• Multi-materials

33

Unclassified

• Army started UARCs why? nsf?

• Schuh: work non-aqueous deposition

• Biotechnology

• Assumption: normal structures are ltwt;

• Low energy cons?

• How does DARPA see GSID helping itself? Ti initiative: structural amorphous metals (SAMS)

• Where is basic material science incubating? Universities: National labs?

• Controlling microstructure?

• Establish property – architectural specs?

• What is the process to bring new ideas and materials to the PMs, PEOs, etc?

• How does the basic research translate to useable materials?

• 61., 6.2, 6.3 appear to be stove piped: how to fix?

Unclassified

Workshop Expectations

• Research Driven Opportunities– 6.1, 6.2 -> What should the GSID follow and support?

– Awareness and participation in Material Science Programs

• Opportunities to integrate– Demonstrator programs (6.3)

– Platform/Product/Part Driven Needs

• PEO GCS, CS&CSS modernization programs

• OEMs

• DLA/Sustainment

• Depots

• Barriers to adoption of new materials?– Environment, safety, cost, weight, size, MRL/TRL

• It is a Workshop

Unclassified

GSID Expectations

• Opportunities– 6.2, 6.3

– PEO GCS, CS&CSS

– OEM

• Why do we have the heaviest SLAT armor?

Unclassified

Needs

• Stronger, lighterweight

• High energy storage devices

• Better processing– Lower cost manufacture methods

– New technology forming methods

– Joining – welding

• Models and Simulations– Understand structures

– Predict materials and properties

• Testing– NDE

– Accelerated corrosion testing

– Available standards

– Standardized test methods 37

Unclassified

Greatest Need

• A guide to traverse the Valley of Death

– Requirements understood by researchers

– Complete technical specs for new materials transferred to PEOs

38

Unclassified

39

GSID Materials Workshop

Review of Issues/Actions from Day 1

• Both PEO’s have commonality and SWAP-C needs• Create GSID/PEO Integration Guide• Avoiding the “Valley of Death” Guide• Road mapping meetings?• PEO TRA Support?• Why is Value Engineering so Hard?• Lightweight track ROI business case – share?• Titanium path forward with DARPA• P&E materials work skipped?• Dan Morse – low temperature semiconductors• Dr. Prater – materials by design• Xtalic – quick win?• Reversible damage sensing elastomer – Q-win?• Tortorelli: CF8C – Plus steel – Cat – Q-win?• What are transition issues to carbon fiber?• Leveraging vehicle light weighting efforts

Unclassified